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Discussion Starter · #1 ·
Hi everyone. Been making great use as a reader on this forum for the better part of a year. Fantastic resource. Unfortunately, I've not been having luck solving my most recent issue so it's time to make my first post.

We've got an '04 Passat GLX 4Motion with 115,000 miles that's been a blast to drive, but about a month ago, my son was getting on the highway when the motor just died. He coasted to a stop and had it towed home.

First thing I did was pull the spark plugs to see to check their condition and see if I was getting any fuel. They were all dry. So, my first thought is I've got something wrong with the fuel system. We check the Fuel Relay and it was clicking. Then tried to see if we could hear the fuel pump turning on, but couldn't so we checked the voltage and the voltage at the pump was good so we decided to change the pump. That wen't okay except that I seem to have put the connectors for the fuel level sender back on incorrectly so now the fuel level sender reads that it has an open or short to plus. Anyway, that turned out to not be the problem as I was able to verify that the fuel pump is coming on now.

Next I worked with a buddy to check and see what we find with VCDS and after clearing all the DTC's we found 1 fault:

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Address 01: Engine Labels: 078-907-551-ATQ.lbl
Part No: 3B0 907 551 DB
Component: 2.8L V6/5V G 0010
Coding: 07751
Shop #: WSC 00028
VCID: 66DEA5060231E911F43-5140
WVWTH63B74P155261 VWZ7Z0C8454560

1 Fault Found:
16496 - Intake Air Temp. Sensor (G42)
P0112 - 35-00 - Signal too Low
Readiness: 0110 1101

-------------------------------------------------------------------------------

After doing a little research we didn't find anything that directly pointed to this causing it to not start but we also noticed that we had a continuous EPC light on
the dash. A little more research and further testing with VCDS we were able to log that the engine was only turning over at about 160rpm's but occasionally would bump up to 280 and cough like it was going to start but not.

I can't remember where we found it but I understand that the rpm's have to be over 200 in order for the fuel rails to open up. This pointed to the Engine Speed Sensor or the ECM. We didn't have a way to test the ECM but checked the Engine Speed Sensor per the test sequence section of the Bentley book. After replacing the Engine Speed Sensor, I'm still getting only 160rpm's via VCDS.

At this point, I'm not sure what to do. Any suggestions would be greatly appreciated.

Thanks everyone.

Karl
 

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PassatWorld Elder
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27,961 Posts
Did you check the timing belt, has it been changed? Can you hear the pump run when the key is first turned? Have you pulled the fuel line to check for flow? Check all fuses?

Not much to go on, but not much will kill a running engine.
 

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Discussion Starter · #3 ·
I checked all the fuses. The fuel pump runs when I apply direct power to it, but I've got a hearing impairment so I can't hear it it's running when I try to start it or not. The timing belt was recently changed along with water pump and thermostat and the car ran fine afterwards. Haven't pulled the fuel line to check for flow as I'm still trying to figure out the best way to go about that test.

Are there any sensors that can be logged with VCDS when trying to start the car that would say if the pump was running or not? Any other tests to run with VCDS or other suggestions would be greatly appreciated.

Thanks.

Karl
 

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PassatWorld Elder
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27,961 Posts
Anything that would kill the engine, should show a code apart from the fuel pump or mechanical damage. The pump could still run, but not have enough pressure to start the car.

Did you check the codes before clearing them all? You may have erased the one needed for diagnosis and it may not return if the engine is not started.

If you have access to a fuel pressure tester, you can pull the hose from just behind the airbox (the one that bolts to the fuel rail) by removing the miniature clamp. If you unbolt the side at the rail, it may leak in cold temps.

If you have fuel pressure, check for spark, a tester can be rented for free at AutoZone. You can also rent a compression tester if there is spark and fuel.
 

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Discussion Starter · #5 ·
I did check the codes. Here's the output from the autorun:

Tuesday,23,June,2015,19:23:32:22052
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 14.10.2.0 (x64)
Data version: 20150311
Ross-Tech: Home


VIN: WVWTH63B74P155261 License Plate: XXXXXX
Mileage: 198760km-123503mi Repair Order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 3B (3B - VW Passat B5 (1997 > 2005))
Scan: 01 02 03 08 15 16 17 19 35 36 37 46 47 55 56 57 58 75 76 77


VIN: WVWTH63B74P155261 Mileage: 198760km-123503miles
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Address 01: Engine Labels: 078-907-551-ATQ.lbl
Part No: 3B0 907 551 DB
Component: 2.8L V6/5V G 0010
Coding: 07751
Shop #: WSC 00028
VCID: 66DEA5060231E911F43-5140
WVWTH63B74P155261 VWZ7Z0C8454560

1 Fault Found:
16496 - Intake Air Temp. Sensor (G42)
P0112 - 35-00 - Signal too Low
Readiness: 0110 1101

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Address 02: Auto Trans Labels: 01V-927-156.lbl
Part No: 3B0 927 156 BA
Component: AG5 01V 2.8l5V USA 2225
Coding: 01102
Shop #: WSC 02336
VCID: 66DEA5060231E911F43-5140

No fault code found.

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Address 03: ABS Brakes Labels: 4B0-614-517.lbl
Part No: 4B0 614 517 H
Component: ABS/ESP allrad 3428
Coding: 04257
Shop #: WSC 00028
VCID: 265EE506C2B12911343-5140

No fault code found.

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Address 08: Auto HVAC Labels: 3Bx-907-044.lbl
Part No: 3B1 907 044 J
Component: CLIMATRONIC B5GP 0006
Coding: 17200
Shop #: WSC 00028
VCID: 2842EB3EC8A53F6106F-5140

6 Faults Found:
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent
00792 - A/C Pressure Switch (F129)
35-00 - -
00603 - Footwell/defroster Flap Positioning Motor (V85)
37-10 - Faulty - Intermittent
01271 - Positioning Motor for Temperature Flap (V68)
37-00 - Faulty
01272 - Positioning Motor for Central Flap (V70)
37-00 - Faulty
01274 - Air Flow Flap Positioning Motor (V71)
37-00 - Faulty

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Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 C
Component: 09 AIRBAG VW61 04 0003
Coding: 12345
Shop #: WSC 00028
VCID: 245AFF0EB48DDB012A7-5140

1 Fault Found:
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent

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Address 16: Steering wheel Labels: 1J0-907-487-A.lbl
Part No: 1J0 907 487 A
Component: Lenkradelektronik 0005
Coding: 00118
Shop #: WSC 00028
VCID: 2F700022ED4B6859C75-5140

1 Fault Found:
00926 - Terminal 30
07-10 - Signal too Low - Intermittent

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Address 17: Instruments Labels: 3B0-920-xx5-17.lbl
Part No: 3B0 920 929 B
Component: KOMBI+WEGFAHRSP VDO V04
Coding: 15235
Shop #: WSC 00050
VCID: 265EE506C2B12911343-5140
WVWTH63B74P155261 VWZ7Z0C8454560

1 Fault Found:
00771 - Fuel Level Sensor (G)
30-00 - Open or Short to Plus

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00028
VCID: 70F2C35E30F537A19EF-5140

No fault code found.

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Address 36: Seat Mem. Drvr Labels: 3B1-959-760.lbl
Part No: 3B1 959 760 E
Component: ∞301
Shop #: WSC 00000 000 00000
VCID: 2F700022BD4B6859C75-5140

1 Fault Found:
01008 - Note; Emergency OFF Switch is Active!
000 - -

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Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 09 Komfortger·t HLO 0003
Coding: 00258
Shop #: WSC 00028
VCID: 37603842151BA0999F5-4B00

Subsystem 1 - Part No: 1C0959801
Component: 09 Tırsteuer.FS KLO 0202

Subsystem 2 - Part No: 1C0959802A
Component: 09 Tırsteuer.BF KLO 0202

Subsystem 3 - Part No: 1C0959811
Component: 09 Tırsteuer.HL KLO 0202

Subsystem 4 - Part No: 1C0959812
Component: 09 Tırsteuer.HR KLO 0202

2 Faults Found:
01179 - Incorrect Key Programming
35-00 - -
01359 - Internal Central Locking Switch; Passenger Side (E198)
27-10 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio Labels: 3B7-035-1xx-56.lbl
Part No: 3B7 035 180 G
Component: Radio NP2 0016
Coding: 04031
Shop #: WSC 00028
VCID: 245AFF0EB48DDB012A7-5140

1 Fault Found:
01336 - Company Data Bus for Comfort System
37-10 - Faulty - Intermittent

-------------------------------------------------------------------------------
Address 75: Telematics Labels: None
Part No SW: 3B0 035 617 G HW: 3B0 035 617 G
Component: Telematik NAR1 0410
Coding: 0041110
Shop #: WSC 02645 444 59123
VCID: 2256F916FE99D53158B-5140

1 Fault Found:
00470 - Company Comfort Databus in Single Wire
012 - Electrical Fault in Circuit - Intermittent

End-------------------------(Elapsed Time: 07:03)--------------------------

I'll see what I can come up with to check the fuel pressure.

Thanks for the tips.

karl
 

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Discussion Starter · #6 ·
Ok. So, at this point, I think I've been able to verify that the engine is not getting fuel. I sprayed starting fluid in the air intake and it started right up. I also pulled the supply line to the fuel rails and when applying external power to the fuel pump, nothing came out. This was in lieu of a fuel pressure gauge since I didn't have the right connectors to hook up the one that the local parts store loans out. Oddly enough, when disconnecting the return line at the fuel pump and applying external power to the pump, I got a steady stream of fuel to come out the return line. I even tried starting the car while doing this and got nothing. How can the fuel pump be pushing fuel out but not to the fuel rails so that it comes back out the return line? Any suggestions anyone?
 

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PassatWorld Elder
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27,961 Posts
Check the voltage on both side of fuse 34. Also check the fuel pump relay, remove the cover and see if the contacts close when power is turned on.
The I think you have your supply/return lines mixed up. If no fuel is going in the supply line, no fuel could come out of the return.
 
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